Case and organizer tray for a power tool

ABSTRACT

A case for a power tool includes a cover member and base member coupled together along a hinge line. The cover and base members are configured to fold together along the hinge line to form an enclosed cavity. A first opening is provided in the case for receiving a first end of a power tool and a second opening is provided in the case for receiving a second end of a power tool. The handle of the power tool serves as the handle for the case. A storage tray includes a plate member having a first and a second half. A plurality of coupling elements are disposed on a surface of the plate member. The plate member is configured to fold along a hinge line such that the coupling elements face outwardly. A carrying case system is also described.

FIELD

This technology relates to a case and an organizer tray for a power tool. In particular, the technology concerns a case that is configured such that the power tool forms a handle of the case and to an organizer tray for the case.

BACKGROUND

Carrying cases for tools are known. They generally include a front cover and a base member that is made of a hard plastic material. The cover fold upon the base member along a hinge line in order to form a case. The cover and/or the base typically have molded inner surfaces that are shaped to accept and hold a power tool, such as a drill, driver, saw, nailer, or other tool. Many cases also provide storage openings inside the case for storing accessories, such as drill bits, saws, nails, screws, dust covers, power cords, etc. One or both of the cover and base member typically include a handle. In some cases, the handle is a molded opening that is formed in both the cover and the base member such that when the cover is closed upon the base member, the openings come together to provide a handle. In other cases, a separate handle is hinged, or otherwise attached, to one or both of the cover and base member.

Trays for holding power tool accessories are known. One type of tray includes a flat base with a plurality of openings for receiving drill bits of various sizes. The tray is formed of a pliable material to allow the drill bits to be inserted into and removed from individual openings formed in the base.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a perspective view of an example case with a power tool coupled to the case;

FIG. 2 is another perspective view of an example case with a power tool coupled to the case;

FIG. 3 is a side view of the case of FIG. 1 with a power tool coupled to the case;

FIG. 4 is a rear view of the case of FIG. 1 with a power tool coupled to the case;

FIG. 5 is a top view of the case of FIG. 1 with a power tool coupled to the case;

FIG. 6 is a perspective view like that of FIG. 1, but with the power tool removed;

FIG. 7 is a side view of the case shown in FIG. 4;

FIG. 8 is a top view of the case shown in FIG. 4;

FIG. 9 is an example organizer tray for use with the example case of FIGS. 1-8;

FIG. 10 is a front view of the example tray;

FIG. 11 is a right side view of the example tray;

FIG. 12 is a left side view of the example tray;

FIG. 13 is a front perspective view of the tray of FIG. 10 folded in half;

FIG. 14 is a top view of the folded tray shown in FIG. 13;

FIG. 15 is a left side view of the folded tray shown in FIG. 13;

FIG. 16 is a perspective view of the case of FIG. 1 shown in an open position with the folded tray of FIG. 13 aligned for positioning in the case;

FIG. 17 is a front view of the case shown in FIG. 16 with the folded tray inserted in a retaining slot within the case;

FIG. 18 is a top view of the case shown in FIG. 16;

FIG. 19 is an exploded perspective view of the case of FIG. 16 with a power tool ready for insertion into the case; and

FIG. 20 is a perspective view of the case and power tool shown in FIG. 19, but with the power tool inserted into the case.

DETAILED DESCRIPTION

In accordance with the teachings described herein, a case for a power tool comprises a first casing section and a second casing section coupled to the first casing section along a casing hinge line. The first and second casing sections are configured to fold together along the casing hinge line to form an enclosed cavity between the first and second casing sections. At least one of the first and second casing sections includes a first opening and a second opening. The first opening is configured to capture a first end of a power tool and the second opening is configured to capture a second end of a power tool such that when a power tool is captured at its first and second ends by the first and second openings, the power tool serves as a handle for the case. At least one capturing member may be associated with one or both of the first and second openings for assisting in capturing the power tool in the corresponding opening. The capturing member may be a rib that is positioned inside the cavity and is configured to mate with a part of a power tool. The first and second casing sections may be made of a plastic material

In one embodiment, the first casing is a cover member and the second casing is a base member, with the first opening being defined in the base member and the second opening being defined in the base member. The first opening may be defined on a side surface of the base member, near the top thereof, and the second opening may be defined on an upper surface of the base member, near the bottom thereof. The first opening may be further defined in the cover member such that the first opening extends between the cover member and the base member.

A plurality of hinges may be disposed along the casing hinge line and a plurality of latching components may disposed between the first and second casing sections to lock the first and second casing sections together when the latching components are in a latched position. Each latching component may include a movable latch portion coupled to one of the first or second casing sections and a catch coupled to the other of the first or second casing sections. The catch may have a surface for lockingly mating with the movable latch portion. Each latch portion may be attached to the respective casing by a latch hinge, and each latch portion may include a lip for mating with the corresponding catch. The hinges along the casing hinge line may be living hinges, and the hinges of the latch portions may be living hinges. In one embodiment, three latching components are provided in spaced relation to one another around an outer periphery of the case.

The case may include at least one coupling member defined in the cavity of the case. The at least one coupling member is associated with at least one of the first and second casing sections and is configured for receiving a storage tray. The coupling member includes a plurality of channels configured to accept the ends of a storage tray to hold the tray in a fixed position within the cavity. The cavity defined by the first and second casing sections in the vicinity of the second opening is configured to receive a battery pack of a power tool. The cavity may further include a plurality of recesses for storing accessories.

In one embodiment, the power tool is a cordless drill having a chuck and a collar at a first end and a battery pack at a second end. The handle of the drill is positioned between the first and second ends of the drill. The first opening is configured to capture the chuck and collar of the drill, and the second opening is configured to capture the battery pack of the drill.

In another embodiment, a storage tray for use with a power tool comprises a plate member having a first half and a second half, with a plurality of coupling elements disposed on at least one of an outer surface of the first half and an outer surface of the second half. A hinge line is defined between the first and second halves. The first and second halves are configured to fold upon one another along the hinge line such that the outer surfaces of the first and second halves face away from one another. The plate member has an open position in which all the coupling elements are positioned in substantially the same plane and a folded position in which the coupling elements on the first half face away from the coupling elements on the second half.

The plate member may have an “H-shaped” profile, with the hinge line being positioned at the center of the H-shape, and the coupling elements being configured to accept tools. The plate member and coupling elements may be made of a plastic material.

In yet another embodiment, a carrying case system for a power tool comprises the case, described above, and at least one storage tray, as described above. The case includes at least one coupling member defined in the cavity between the first and second casing sections that is configured to couple the at least one tray with the cavity when the tray is in a folded position. The coupling member may be a pair of channels disposed in the cavity, with the channels being positioned in opposite relation to one another and configured to mate with first and second ends of the storage tray.

With reference now to the drawings, FIGS. 1-8 and 16-20 depict an example case 10 for a power tool 12. The case 10 has an “L-shape”, with an upper vertical leg 14 and a lower horizontal leg 16. The case 10 includes a first casing section 18 and a second casing section 20. Openings 22, 24 are provided in the case 10 for accepting the ends 26, 28 of a power tool 12. The main body 30 of the power tool 12 is exposed to the exterior while the ends 26, 28 of the power tool 12 are captured within the case 10. The handle 32 of the power tool 12 serves as a handle for the case 10.

The first casing section 18 is a cover member and the second casing section 20 is a base member. The cover member 18 and base member 20 are coupled together along a common hinge line 34 to form a case 10 having an interior. In the depicted embodiment, a plurality of hinges 36 are disposed along the casing hinge line 34 in the form of living hinges. Alternatively, mechanical hinges that are attached to the casing sections 18, 20 may be utilized, or other known hinges.

The interior of the case 10 includes a cavity 38 that is defined between the inner surface 40 of the first casing section 18 and the inner surface 42 of the second casing section 20. The interior of each casing section includes a plurality of individual recesses 44 that are separated by ribs 46, shown best in FIGS. 16 and 17. The ribs 46 help to strengthen the casing sections 18, 20. The recesses 46 are configured to allow the case 10 to mate with the first and second ends 26, 28 of a power tool 12. In the depicted embodiment, a cordless hand-held power drill is described. Other types of tools may be utilized with the example case 10, such as a driver, a polisher, a reciprocating saw, and other known power tools. Cordless and corded power tools may derive a benefit from the example case 10. The cordless drill is depicted herein as an example of one use of the storage case 10. As is evident, different configurations of cases can be manufactured for different power tools, according to the example described herein.

The individual recesses 44 that are formed on the interior of the casing sections 18, 20 are used to capture part of the power tool 12 between the first and second casing sections 18, 20, as will be discussed in greater detail below. The recesses 44 may also be utilized for storing accessories for use with the power tool 12, such as a charger for a cordless power tool, screw and drill bits, power cords, covers, tool kits or trays, and other accessories as known by those of skill in the art.

As shown in FIG. 16, the base member 20 has a depth and the cover member 18 has a depth. In the depicted embodiment, the base member 20 has a depth that is greater than the depth of the cover member 18. As a result, the base member 20 is configured to accept a greater portion of the power tool 12 in its interior than is the cover member 18. In alternative embodiments that are not shown, the cover member 18 and base member 20 may be approximately the same depth, or the cover member 18 may be deeper than the base member 20. The size and configuration of the first and second casing sections 18, 20 are dependent upon the particular application.

Referring to FIGS. 6 and 7, the storage case 10 has a first opening 22 for capturing a first end 26 of the power tool 12 and a second opening 24 for capturing a second end 28 of the power tool 12. In the case of a cordless drill 12, the first opening 22 is defined near the top end 48 of the case 10 for coupling with the output end 50 of the drill 12 and the second opening 24 is defined near the bottom end 52 of the case 10 for coupling with the battery pack 54 of the drill 12. Other power tools may require different positions for the openings, the example case 10 not being limited to a particular location for the openings.

As depicted in FIGS. 6, 7, 19 and 20, the first opening 22 has a size to allow the collar 56 and chuck 58 of the drill 12 to enter the interior of the base member 20. The first opening 22 includes an outer aperture 60 on the base member 20 that surrounds a portion of the collar 56 of the drill 12 and an inner capture rib 62 on the base member 20 that is positioned between the chuck 58 and the collar 56. The inner capture rib 62 is positioned inside the base member 20, is formed integrally as one of the interior ribs 46 in the cavity 38 of the case 10, and partially surrounds the drill 12 between the collar 56 and the chuck 58. Both the inner capture rib 62 and the outer aperture 60 are semicircular in shape. In addition, part of the first opening 22 is formed through the cover member 18, in the form of a semi-circular cut out 64 on the edge of the cover member 18. The cut out 64 is adjacent the outer aperture 60 on the base member 20 when the cover and base members 18; 20 are folded together in a closed position. The semi-circular cut out 64 on the cover member 18 mates with the semi-circular outer aperture 60 on the base member 20 to provide an opening 22 that is sized to accept the entire collar 56 of the cordless drill 12.

The second opening 24 has a size to accommodate the base of the handle portion 32 of the power tool 12, at a point where the battery pack 54 mates with the handle portion 32. The second opening 24 is semi-circular and is positioned above a recess within the interior of the base member 20 that is sized to accept the battery pack 54. The first and second openings 22, 24 are configured to capture the first and second ends 26, 28 of the power tool 12 within the case 10. When the cover member 18 is folded onto the base member 20 to close the case 10, the power tool 12 is fixedly held within the case 10 at its ends 26, 28 and the handle portion 32 and part of the main body 30 of the power tool 12 extend from the case 10. The handle 32 of the power tool 12 serves as a handle for the case 10.

The disclosed example case 10 depicts the cordless drill 12 as being captured at certain positions on the drill 12. The case 10 could be altered in size and configuration to capture the cordless drill 12 at other locations on the tool 12. For instance, the drill 12 could be captured at a point on its main body 30 instead of around its collar 56. As is evident, variations of the disclosed example are possible based upon the teachings provided herein.

The first and second casing sections 18, 20 may include a lip 66 around the peripheral edges of each section. The lip 66 may be configured to mate with a complementary lip 66 on the opposing casing section.

When the case 10 is closed so that the cover member 18 is positioned on the base member 20, the casing sections 18, 20 may be latched together via latching components 68. The latching components 68 include a movable latch portion 70 and a fixed catch 72. The movable latch portion 70 is in the form of an elongated member that extends in length from one casing section to the adjoining casing section. In the depicted embodiment, the latch portion 70 is attached to the base member 20 and the catch 72 is attached to the cover member 18. The latch portion 70 includes a lip 74 that mates with the catch 72 to maintain the case 10 in a closed and locked position when the latch portion 70 is mated with the corresponding catch 72. As shown in FIG. 6, three latching components 68 are provided and are spaced relative to one another. A first latch is provided along an upper wall of the case 10, a second latch is provided at an intermediate position on the side wall of the case 10, and a third latch is provided at a lower position on the side wall of the case 10.

Each latch portion 70 is attached to the cover member 18 via a hinge 76 and the each catch is attached to the base member 20. In the depicted embodiment, the hinge 76 is a living hinge, although alternative types of hinges may be utilized to couple the latch portions 70 to the cover member 18. Fewer or greater latch portions 70 may be utilized, if desired. In addition, the latch portion 70 may alternatively be positioned on the base member 20, with the corresponding catch 72 being positioned on the cover member 18. As shown, the latch portion 70 and corresponding catch 72 are preferably aligned with one another in order to mate with one another when the latch portion 70 is in a contact with the catch 72. The latching components 68 may be integrally formed with the casing sections 18, 20, or may be attached via any known attachment mechanism.

The latch portions 70 may all be the same size, or may be different sizes. In the depicted embodiment, the intermediate latch portion 70 has a length that is greater than the length of the upper and lower latch portions 70. The larger latch portion 70 provides greater latching strength than the smaller latch portions 70. In the depicted embodiment, it was preferred that the intermediate latch portion 70 be stronger than the other latch portions, although the intermediate latch portion 70 could be the same size as the other latching portions.

Referring to FIGS. 16-17 and 20, the interior recesses 44 may be configured to mate with a storage organizer tray 80. In the depicted example, the base member 20 includes opposed channels or slots 78 that are positioned on inner ribs 46 of the base member 20. The opposed channels 78 are configured to mate with a storage tray 80 at a top and a bottom end of the tray. The tray 80 has ends 82 that slide into the channels 78 and the channels 78 hold the tray 80 in position within the base member 20 when installed.

The interior recesses 44 of the cover and base members 18, 20 may be configured in any known manner to accept items for storage. For example, coupling elements, such as members for coupling drill bits or screw bits may be attached or molded into the inner surfaces of the base and cover members 20, 18. Individual compartments (not shown) with or without covers may be formed within the recesses 44 of the base and cover members 20, 18. Lashes or other connectors (not shown) may be provided. Other alternatives may also be utilized for storing accessories in the interior cavity 38 of the case 10, the options not being limited to those depicted in the instant example.

The base member 20, cover member 18, latches 70 and catches 72, in one embodiment, are made of polypropylene (“PP”) and are integrally formed during the molding process. Other plastic materials may be alternatively used. Materials other than plastic may alternatively be used. The base member 20 and cover member 18 may be manufactured using an insert molding method, or via any known manufacturing method.

FIGS. 9-12 depict an example insert storage organizer tray 80 that may be utilized for storing accessories, such as drill bits or other power tool accessories. The tray includes a plate 86 with a plurality of coupling elements 84 positioned on the plate 86. The coupling elements 84 extend outwardly from a surface of the plate 86 and are configured to couple tools and accessories to the plate 86.

The plate 86 includes a first half 88 and a second half 90, with a bridge 92 positioned between the first and second halves 88, 90. In the depicted embodiment, the profile of the plate 86 is “H-shaped,” with the bridge 92 being formed as the center of the “H-shape.” The bridge 92 includes a hinge line 94 and the plate 86 is configured to bend along the hinge line 94 so that the first and second halves 88, 90 fold on top of one another. The plate 86 has a reduced cross-section along the hinge line 94. The folding storage tray 80 allows for greater storage capacity while allowing the user to more easily access the components attached to the coupling elements 84 when the tray 80 is in use and not in storage.

Referring to FIG. 9, the plate 86 is a substantially flat member, although a non-flat member could be utilized. The coupling elements 84 are positioned on an outer side 96 of the plate 86. The coupling elements 84 includes a plurality of fasteners for coupling various accessories to the plate 86. Such accessories include drill bits, screw bits, screws, nails, and other types of tools as known by those of skill in the art. The coupling elements 84 may be positioned directly on the flat surface of the plate 86, or may be positioned on raised platforms 98 that are defined on the plate 86. By positioning the coupling elements 84 on a single side of the plate 86, the plate 86 may be folded in half and the inner sides 100 may be positioned directly against one another to provide the smallest possible width for the tray 80. In addition, the tray 80 may be folded flat because the flat inner surfaces 100 abut one another when the plate 86 is folded. This is useful for storage purposes, since trays 80 of this sort are often installed in tight fitting recesses 44 within cases, as discussed above in connection with the storage case 10.

Alternatively, although not shown, the coupling elements 84 may be positioned on both the inner and outer sides 100, 96 of the plate 86. When the coupling elements 84 are positioned on the inner sides of the plate 86, care must be taken to ensure that the tray 80 can properly fold in half and that accessories do not bind against each other when the plate 86 is folded in half for storage. In this case, the user would be required to flip the tray 80 from one side to the other to access all the accessories.

The plate 86 includes outwardly extending shoulders 102 that extend perpendicularly from the plate 86, near the side edge 82. As discussed above, the inner side 100 of the plate 86 is flat while the outer side 96 of the plate 86 includes outwardly extending coupling elements 84. The shoulders 102 are spaced from the side edge 82 so that a small section of the flat plate 86 extends outwardly from the position of the shoulders 102. The shoulders 102 have a height similar to the height of the coupling elements 84 and may provide protection to the elements from damage. When the plate 86 is folded in half, as shown in FIGS. 13 and 14, the shoulders 102 and flat plate 86 form an “H”-shaped cross-section with protrusions 104 that extend outwardly from the sides of the “H” shape and with the coupling elements 84 extending outwardly from the flat plate surfaces. As shown in FIG. 16, the protrusions 104 are utilized to couple with the opposed channels or slots 78 that are positioned on the interior of one of the recesses 44 of the base member 20. The protrusions 104 are shaped to fit into the channels or slots 78 and the tray 80 may be slid into the channels or slots 78.

The bridge 92 includes a hinge 106 in the form of a living hinge that is molded into the plate 86. The living hinge is provided by the area of reduced cross-section on the bridge 92. Other types of hinges, such as mechanical hinges, may alternatively be used. In addition, the bridge 92 includes several ridges 108 that extend outwardly when the plate 86 is folded in half. When folded in half, the bridge 92 forms a tab-like structure 110 that extends outwardly from the side of the storage tray 80. The ridges 108 on the tab-like structure 110 may be useful to the user in inserting and withdrawing the tray 80 from a storage position within a storage case 10, as shown in FIG. 17. The ridges 108 provide a gripping surface for the user.

As shown in FIG. 9, indicia 112 such as stamp art or illustrations may be positioned on the surface of the plate 86. The indicia 112 is useful to the user in identifying the types of accessories that are stored on the tray 80, such as bits or other parts. Indicia 112 also provides a helpful reminder to the user when attempting to reinsert accessories that have been removed from the tray 80.

The above-described tray 80 and storage case 10 are convenient for the user and provide portability in carrying a power tool 12 and associated accessories as one package. Because part of the power tool 12 is positioned outside the case 10, more room for storage is provided in the case 10. The case 10 includes the removable storage tray 80 and includes room for carrying an extra battery pack and charger.

In one embodiment, the insert tray 80 may be made of a Polypropylene (“PP”) material and may be manufactured using an injection molding process. Other types of materials may be utilized for the insert tray 80. Other types of manufacturing processes may be utilized in manufacturing the tray 80. The coupling elements 84 may be integrally formed with the plate 86 during the manufacturing process, or may be attached to the plate 86 using any known technique.

While various features of the claimed embodiments are presented above, it should be understood that the features may be used singly or in any combination thereof. Therefore, the claimed embodiments are not to be limited to only the specific embodiments depicted herein.

Further, it should be understood that variations and modifications may occur to those skilled in the art to which the claimed embodiments pertains. The embodiments described herein are exemplary. The disclosure may enable those skilled in the art to make and use embodiments having alternative elements that likewise correspond to the elements recited in the claims. The intended scope may thus include other embodiments that do not differ or that insubstantially differ from the literal language of the claims. The scope of the example embodiments is accordingly defined as set forth in the appended claims. 

1. A case for a power tool comprising: a first casing section; and a second casing section coupled to the first casing section along a casing hinge line, wherein said first and second casing sections are configured to fold together along the casing hinge line to form an enclosed cavity between the first and second casing sections, with at least one of said first and second casing sections including a first opening and a second opening, said first opening configured to capture a first end of a power tool and said second opening configured to capture a second end of a power tool such that when a power tool is captured at its first and second ends by the first and second openings, the power tool serves as a handle for the case.
 2. The case of claim 1, wherein the first and second casing sections are made of a plastic material.
 3. The case of claim 1, wherein the first casing is a cover member and the second casing is a base member, the first opening is defined in the base member, and the second opening is defined in the base member.
 4. The case of claim 1, wherein at least one capturing member is associated with one or both of the first and second openings for assisting in capturing the power tool in the corresponding opening.
 5. The case of claim 4, wherein the capturing member is a rib that is positioned inside the cavity and is configured to mate with a part of a power tool.
 6. The case of claim 3, wherein the first opening is defined on a side surface of the base member, near the top thereof, and the second opening is defined on an upwardly facing surface of the base member, near the bottom thereof.
 7. The case of claim 3, wherein the first opening is further defined in the cover member such that the first opening extends between the cover member and the base member.
 8. The case of claim 1, further comprising a plurality of hinges disposed along the casing hinge line and a plurality of latching components disposed between the first and second casing sections to lock the first and second casing sections together when the latching components are in a latched position.
 9. The case of claim 8, wherein each latching component includes a movable latch portion coupled to one of the first or second casing sections and a catch coupled to the other of the first or second casing sections, said catch having a surface for lockingly mating with the movable latch portion.
 10. The case of claim 9, wherein each latch portion is attached to the respective casing by a hinge, and each latch portion includes a lip for mating with the corresponding catch.
 11. The case of claim 10, wherein the hinges along the casing hinge line are living hinges, and the hinges of the latch portions are living hinges.
 12. The case of claim 8, wherein three latching components are provided in spaced relation to one another around at least a portion of an outer periphery of the case.
 13. The case of claim 1, further comprising at least one coupling member defined in the cavity, said at least one coupling member being associated with at least one of the first and second casing sections and being configured for receiving a storage tray.
 14. The case of claim 13, wherein the coupling member includes opposed channels configured to accept the ends of a storage tray to hold the tray in a fixed position within the cavity.
 15. The case of claim 1, wherein the cavity defined by the first and second casing sections in the vicinity of the second opening is configured to receive a battery pack of a power tool.
 16. The case of claim 1, wherein the power tool is a cordless drill having a chuck and a collar at a first end and a battery pack at a second end, with a handle of the drill being positioned between the first and second ends, the first opening is configured to capture the chuck and collar of the drill, and the second opening is configured to capture the battery pack of the drill.
 17. The case of claim 1, wherein the cavity includes a plurality of recesses for storing accessories.
 18. A storage tray for use with a power tool comprising: a plate member having a first half and a second half, with a plurality of coupling elements disposed on at least one of an outer surface of the first half and an outer surface of the second half, wherein a hinge line is defined between the first and second halves, with the first and second halves being configured to fold upon one another along the hinge line such that the outer surfaces of the first and second halves face away from one another, said plate member having an open position in which all the coupling elements are positioned in substantially the same plane and a folded position in which the coupling elements on the first half face away from the coupling elements on the second half.
 19. The storage tray of claim 18, wherein the plate member has an “H-shaped” profile, with a bridge member positioned in the center of the “H-shape,” with the hinge line being positioned on the bridge member, with the coupling elements being configured to accept tools; and the plate member and coupling elements are made of a plastic material, wherein when the plate is folded in half along the hinge line, the bridge member forms a tab that is configured for gripping by the user.
 20. A carrying case system for a power tool comprising: the case of claim 1; and at least one storage tray according to claim 18, wherein the case includes at least one coupling member defined in the cavity between the first and second casing sections that is configured to couple the at least one tray with the cavity when the tray is in a folded position.
 21. The carrying case system of claim 20, wherein the at least one coupling member is a pair of channels disposed in the cavity, said channels being positioned in opposite relation to one another and configured to mate with first and second ends of the storage tray. 